Apparatus and method for angular and rotational additive manufacturing

Abstract

An apparatus for powder-based additive manufacturing is described. The build unit(s) of the apparatus includes a powder delivery mechanism, a powder recoating mechanism and an irradiation beam directing mechanism. The build unit is attached to a positioning mechanism that provides the build unit with independent movements in at least two dimensions. The build platform of the apparatus is rotating and preferably vertically stationary. Embodiments of the build unit that further includes a gas-flow mechanism and the build platform having a dynamically grown wall are also described. An additive manufacturing method using the apparatus involves rotating the build platform and repetitive cycles of moving the build unit(s) in a radial direction to deposit at least one layer of powder, and irradiating a selected portion of the powder to form a fused additive layer.

1 . An additive manufacturing apparatus, comprising:
 at least one build unit comprising a powder delivery mechanism, a powder recoating mechanism and an irradiation beam directing mechanism;   a rotating build platform; and   a positioning mechanism configured to provide independent movement of the at least one build unit in at least two dimensions that are substantially parallel to the rotating build platform.   
     
     
         2 . The additive manufacturing apparatus according to  claim 1 , wherein the positioning mechanism is further configured to provide independent movement of the at least one build unit in a third dimension that is substantially perpendicular to the rotating build platform. 
     
     
         3 . The additive manufacturing apparatus according to  claim 1 , wherein the positioning mechanism is further configured to provide independent movement of the at least one build unit around at least one rotational axis. 
     
     
         4 . The additive manufacturing apparatus according to  claim 1 , wherein the rotating build platform is vertically stationary. 
     
     
         5 . The additive manufacturing apparatus according to  claim 1 , wherein the at least one build unit further comprises a gas-flow mechanism configured to provide a substantially laminar gas flow to at least one build area within the build platform. 
     
     
         6 . The additive manufacturing apparatus according to  claim 1 , wherein the irradiation beam directing mechanism further comprises a laser source or an electron source. 
     
     
         7 . The additive manufacturing apparatus according to  claim 6 , wherein the irradiation beam directing mechanism emits and directs a laser beam at an angle that is substantially perpendicular to a build area within the build platform. 
     
     
         8 . The additive manufacturing apparatus according to  claim 6 , wherein the irradiation beam directing mechanism emits and directs an electron beam at an angle that is substantially perpendicular to a build area within the build platform. 
     
     
         9 . The additive manufacturing apparatus according to  claim 1 , wherein the powder delivery mechanism comprises a powder dispenser, wherein
 the powder dispenser comprises at least one powder storage compartment, and at least a first gate and a second gate;   the first gate is operable by a first actuator to allow opening and closing of the first gate;   the second gate is operable by a second actuator to allow opening and closing of the second gate; and   each of the first gate and the second gate is configured to control the dispensation of powder from the at least one storage compartment onto a build surface within the build platform.   
     
     
         10 . The additive manufacturing apparatus according to  claim 1 , wherein the rotating build platform has an annular configuration. 
     
     
         11 . A method of manufacturing at least one object, comprising:
 (a) rotating a build platform;   (b) depositing powder from at least one build unit;   (c) irradiating at least one selected portion of the powder to form at least one fused layer; and   (d) repeating at least step (d) to form the object;   wherein the build unit is moved in a radial direction during the manufacture of the at least one object.   
     
     
         12 . The method according to  claim 11 , further comprising leveling of the at least one selected portion of the powder. 
     
     
         13 . The method according to  claim 11 , wherein the build unit comprises a powder delivery mechanism, a powder recoating mechanism and an irradiation beam directing mechanism. 
     
     
         14 . The method according to  claim 13 , wherein the irradiation beam directing mechanism comprises a laser source or an electron source. 
     
     
         15 . A method of manufacturing at least one object, comprising:
 (a) rotating a build platform;   (b) depositing powder from at least one build unit;   (c) irradiating at least one selected portion of the powder to form at least one fused layer; and   (d) repeating at least step (d) to form the object;   wherein the build unit is moved in a radial direction during the manufacture of the at least one object and wherein a build wall retains unfused powder about the at least one object.   
     
     
         16 . The method according to  claim 15 , further comprising leveling of the at least one selected portion of the powder. 
     
     
         17 . The method according to  claim 15 , wherein the build unit comprises a powder delivery mechanism, a powder recoating mechanism and an irradiation beam directing mechanism. 
     
     
         18 . The method according to  claim 15 , wherein the irradiation beam directing mechanism comprises a laser source or an electron source. 
     
     
         19 . The method according to  claim 15 , wherein the object as an annular object. 
     
     
         20 . The method according to  claim 15 , wherein the object is selected from the group consisting of a turbine or vane shrouding, a central engine shaft, a casing, a compressor liner, a combustor liner and a duct.